Method for Catalytic Surface Protection

ABSTRACT

A method for protecting catalytic metal-based sensor for sensing the presence of hydrogen in an environment comprising, depositing a protective layer on said sensor, said protective layer being permeable to hydrogen.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional application of U.S. patent applicationSer. No. 11/161,874, filed on Aug. 19, 2005.

CONTRACTUAL ORIGIN

The United States Government has rights in this invention under ContractNo. DEA36-99GO10337 between the U.S. Department of Energy and theNational Renewable Energy Laboratory, a Division of Midwest ResearchInstitute.

TECHNICAL FIELD

A hydrogen permeable protective coating for a surface, preferably acatalytic metal-based surface, wherein the dissociation of hydrogen intoatomic hydrogen is preserved, namely, the catalytic activity is allowedto proceed without contamination. One such embodiment includes aprotective coating for a catalytic metal-based surface (e.g., a sensoror other detecting device for sensing the presence of a hydrogen gas.More particularly, a protective coating for a catalytic metal-basedhydrogen sensor having a hydrogen, catalyst palladium (Pd) layer,(however, the layer may also comprise or be composed of platinum groupmetals and their alloys, e.g., palladium copper alloys and palladiumsilver alloys.) Another embodiment includes applications to thecatalytic activity of platinum group metal surfaces involving hydrogendissociation for fuel cell anodes.

BACKGROUND

Hydrogen gas is clean, non-polluting fuel and chemical reagent, which iscurrently used in many industries. With the demand for hydrogen growingevery year and the fact the hydrogen is explosive at only a four (4%)percent concentration in air, the ability to detect hydrogen gas leakseconomically and with inherent safety is desirable and could facilitatecommercial acceptance of hydrogen fuel in various applications. Forexample, hydrogen-fueled passenger vehicles will require hydrogen leakdetectors to signal the activation of safety devices such as shutoffvalves, ventilating fans, and alarms. In fact, such detectors will berequired in several key locations within a vehicle—namely, wherever aleak could pose a safety hazard. Therefore, it is critically importantto carefully measure, monitor, and strictly control hydrogen whereverand whenever it is used.

The real and perceived hazards of hydrogen fuel use, its production, andstorage require extensive safety precautions. Local, state and federalcodes must be put in place before any serious movement can be madetowards a hydrogen based energy future. Currently, commercial hydrogendetectors are not practical for widespread use, particularly intransportation industry applications, because commercial detectors aretoo bulky, expensive, and dangerous.

There exist several hydrogen sensors having a palladium layer that isparticularly attractive for transportation industry applications. Thesehydrogen sensors are termed Hydrogen Field Effect Transistors (HFET),thick film (e.g., incorporating a palladium alloy paste), thin film, andfiber optic. The HFET construction uses a thin film of Pd as the metalcontact controlling the device. The presence of hydrogen results in themigration of atomic hydrogen to the interface between the metal film andthe insulator, which results in change in the output of the device thatis scaled to the hydrogen concentration. The thick film device uses athick film Pd alloy paste to form a four-resistor network (i.e., aWheatstone bridge) on a ceramic substrate. The configuration is suchthat two opposed resistors result in a change in resistivity of thethick film material and a shift in the balance point of the bridge,which can be scaled to the hydrogen concentration. The thin film deviceis equivalent in design to the thick film, with only much thinner films(typically vacuum deposited) used as the resistors.

The fiber optic hydrogen sensor is a gasochromic-type (i.e., one thatchanges color when activated by hydrogen) sensor and is available in avariety of configurations with coatings, typically either palladium orplatinum, at the end of an optical fiber that sense the presence ofhydrogen in air. When the coating reacts with hydrogen, the opticalproperties of the coating are changed. Light from a centralelectro-optic control unit is projected down the optical fiber where thelight is either reflected from the sensor coating back to a centraloptical detector, or is transmitted to another fiber leading to thecentral optical detector. A change in the reflected or transmittedintensity indicates the presence of hydrogen. While the fiber opticdetector offers inherent safety by removing the application ofelectrical power and by reducing signal-processing problems byminimizing electromagnetic interference, critical detector performancerequirements (i.e., for all four configurations described above) includehigh selectivity, response speed, and durability as well as potentialfor low-cost fabrication. The optical senor is not necessarily limitedto a fiber optic delivery system but may be included on any opticalelement.

Unfortunately, all of the conventional catalytic metal-based hydrogensensors have the potential for degradation in their performance overtime due to mechanisms that are inherent in their construction, a resultof their cyclic interaction with hydrogen, or contamination fromimpurities in the environments in which they will be used, While variousattempts have been made to protect the palladium or platinum catalyticsurfaces, these attempts have not significantly improved sensorperformance. Therefore, a need exists to limit degradation therebyallowing hydrogen sensors to operate over extended periods of time inthe presence of contaminants.

Another application is in the proton electrolyte membrane (PEM) fuelcell. This fuel cell is an electrochemical device that produceselectricity from a combined chemical reaction and electrical chargetransport. The device uses a simple chemical process to combine hydrogenand oxygen into water, producing an electric current in the process. Atthe anode, hydrogen molecules are dissociated by a metallic catalyst(usually platinum) into hydrogen atoms, which eventually gives upelectrons to form hydrogen ions. The electrons travel through anexternal circuit to produce usable electric energy while the hydrogenions are transported internally to the cathode where they both combinewith oxygen to form water. The platinum catalyst of the fuel cell anodeis subject to degradation by contaminants similar to that of catalyticmetal-based hydrogen sensor. Application of a protective coating to thesurface of the anode of the platinum catalyst to prevent fouling andmaintain the catalytic activity of hydrogen dissociation is advantageousto fuel cell performance.

The foregoing examples of the related art and limitations relatedtherewith are intended to be illustrative an not exclusive. Otherlimitations of the related art will become apparent to those of skill inthe art upon a reading of the specification and a study of the drawing.

SUMMARY

The following embodiments and aspects thereof are described andillustrated in conjunction with systems, tools and methods that aremeant to be exemplary and illustrative, not limiting scope. In variousembodiments, one or more of the above-described problems have beenreduced or eliminated, while other embodiments are directed to otherimprovements.

An exemplary, preferably amorphous (i.e., a lack of long-rangecrystalline order) hydrogen permeable protective coating for catalyticmetal surfaces is disclosed. This exemplary embodiment has unique andnovel application for sensing the presence of hydrogen gas in anenvironment. The exemplary coating material comprises a layer permeableto hydrogen with the layer being deposited on a surface, for example, asensor between the metal catalyst layer and the environment.

Accordingly, an exemplary protective coating for a surface comprises alayer permeable to hydrogen, the coating being deposited on a catalystlayer, wherein the catalytic activity of the catalyst layer ispreserved. In the disclosed exemplary protective coating for thecatalyst layer is a carbon material which is preferably amorphous; itmay be deposited using a vapor deposition process, preferably a plasmaenhanced chemical vapor deposition process and the protective coating ispreferably deposited at room temperature. The catalyst layer is composedof platinum group metals, and/or platinum group metals and their alloys.The exemplary protective coating further includes a chromogenic layerunderlying the catalyst layer; and a substrate layer underlying thechromogenic layer. However, it will be apparent to those skilled in theart that the protective layer may be understood to overlie the catalystlayer. Under these circumstances the catalyst layer would accordinglyoverlie the chromogenic layer; and the chromogenic layer would overlie asubstrate layer.

Additionally, a sensor for sensing the presence of hydrogen gas in anenvironment is disclosed, comprising: a protective layer permeable tohydrogen; a catalyst layer deposited on said protective layer; achromogenic layer deposited on said catalyst layer; and a substratelayer deposited on said chromogenic lawyer, wherein the catalyticactivity of the catalyst layer is preserved.

Further, an exemplary method for protecting catalytic metal-based sensorfor sensing the presence of hydrogen in an environment is disclosed bydepositing a protective layer on the sensor, wherein protective layer ispermeable to hydrogen.

In addition to the exemplary aspects and embodiments described above,further aspects and embodiments will become apparent by reference to thedrawings and by study of the following descriptions.

BRIEF DESCRIPTION OF THE DRAWING

An exemplary embodiment is illustrated in the referenced figure of thedrawing. It is intended that the embodiment and figure disclosed hereinis to be considered illustrative rather than limiting.

FIG. 1 is a sectional view of an exemplary protective coating for acatalytic metal-based hydrogen sensor.

DETAIL DESCRIPTION

As illustrated in FIG. 1, an exemplary protective coating (material orlayer), indicated generally as 10, for catalytic metal (includinggasochromic) sensor 12 is used sensing the presence of hydrogen gas (asindicated by the arrow). While sensor 12 can detect different types ofgas on a surface or in an environment, including, but not limited to,rooms buildings, chemical process plants, refineries, etc., theconstruction and design of senor 12 especially suits the sensing ofhydrogen leaks in hydrogen-fueled vehicles or similar applications.Therefore, in discussing exemplary protective coating 10 of sensor 12,applicants will particularly describe sensor 12 in conjunction withtransportation (namely, vehicle) use. It should be noted, however, thatany variety of catalytic metal-based sensors including, but not limitedto, HFET, thick film, thin film, and fiber optic sensors, are envisionedand contemplated by those skilled in the art.

The sensor 12 has a substrate layer 14, a chromogenic layer 16, and acatalyst layer 18. The catalyst layer 18 underlies protective coatinglayer 10; chromogenic layer 16 underlies catalyst layer 18; andsubstrate layer 14 underlies chromogenic layer 16. The catalyst layer 18is preferably composed or comprised of palladium, platinum, or theiralloys, such that when exposed to the atmosphere it is reactable to thepresence of hydrogen in the environment. While catalyst layer 18 hasbeen described as being comprised of palladium, platinum, or theiralloys, catalyst layer 18 may be composed of other appropriate materialsfor example, the platinum group metals (platinum, palladium, rhodiumiridium, ruthenium, and osmium). Moreover, many of their alloys areexceptionally good catalysts as will be apparent to those skilled in theart. Among these, palladium and is alloys work exceptionally well forapplications in hydrogen sensors, because of their ability to dissociatemolecular hydrogen and their very high diffusion constants for atomichydrogen, allowing rapid transport through or to the sensing elementand/or material.

During the sensing operations of sensor 12 in an environment, thereaction between the hydrogen gas and chromogenic layer 16 or thecatalyst layer 18 changes the chromogenic layer or the catalyst layer(or both) material's optical properties allowing sensor 12 to sense thepresence of hydrogen. Protection of the chromogenic layer 16 andcatalyst layer 18 from any contaminants. present in the environment(while simultaneously allowing hydrogen permeation) is important for thedetection of hydrogen gas in the environment. If the chromogenic layer16 or the catalyst layer 18 is comprised (e.g., the catalytic hydrogendissociation sites on the surface of the catalyst becomes poisoned) bycontaminants, sensor 12 will fail to function properly leading to thepossible failure of hydrogen gas detection in the environment.

Therefore, protective coating 10 is both a protective (i.e., shielding)and hydrogen permeable layer deposited on the catalyst layer 18 toprotect the chromogenic layer 16 and the catalyst layer 18 of sensor 12.Preferably, the protective coating 10 is a hydrogen permeable carboncoating deposited on the catalyst layer 18 by using any number of vapordeposition processes, however, the preferred method is a plasma-enhancedchemical vapor deposition processes, preferable at room temperature. Asan example of the plasma-enhanced chemical vapor deposition process, theradio frequency (RF) is 150 W, the substrate 14 temperature is thirty(30°) degrees C; the system pressure is 0.6 torr. Ethylene is theprocessing gas and the flow rate is twenty (20) sccm. Once deposited,the protective carbon coating 10 possess the characteristics of anamorphous structure, which is permeable to hydrogen but filters theenvironment's air prior to any contaminants reaching the chromogeniclayer 16 and catalyst layer 18. Those skilled in the art will appreciatethat a wide variety of system parameters (power, pressure, temperature,etc.) will result in variety of successful coatings.

As will be understood by a person skilled in the art, the protectivecoating 10 can be deposited or applied to catalyst layer 18 by a varietyof techniques at variety of temperatures. Describing the protectivecoating 10 as being deposited on the catalytic layer 18 by a chemicalvapor deposition technique at room temperature is only one of manydifferent deposition techniques and other techniques will be apparent tothose skilled in the art.

The carbon coating 10 is permeable to hydrogen but can act effectivelyas a diffusion barrier to contaminant gas molecules, such ashydrocarbon, carbon monoxide, and sulfur-bearing gases, includingothers. Application of the protective carbon coating 10 to the palladiumor platinum catalytic layer 18 of sensor 12 greatly improves thestability and durability of the sensor with a minimum compromise ordegradation in sensor performance. It should be noted that the carboncoating 10 is also applicable to protect gas separation devices havingplatinum group metals or their alloys as the catalytic and/or functionallayer.

The protective coating 10 extends or increases the lifetime of sensor 12in the presence of harmful contaminants and provides effectiveprotection of palladium- and platinum-based hydrogen sensors. In fact,the protective coating 10 is also applicable wherever a platinum groupmetal or alloy layer is used and is use is not limited to gasochromichydrogen sensors.

While a numbers of exemplary aspects and embodiments have been discussedabove, those of skill in the art will recognize certain modifications,permutations, additions and sub combinations thereof. It is thereforeintended that the following appended claims and claims hereafterintroduced are interpreted to include all such modifications,permutations. additions and sub-combinations as are within their truespirit and scope.

1. A method for protecting a catalytic metal-based sensor for sensingthe presence of hydrogen in an environment comprising depositing aprotective layer on said sensor, said protective layer being permeableto hydrogen.
 2. The method as defined by claim 1, wherein saidprotective layer is deposited at room temperature.
 3. The method asdefined by claim 1, wherein said protective material is a carbonmaterial.
 4. The method as defined by claim 3, wherein said carbonmaterial is amorphous.
 5. The method as defined by claim 1, wherein saidprotective layer is deposited using a vapor deposition process.
 6. Themethod as defined by claim 5, wherein said deposition process is plasmaenhanced chemical vapor deposition process.